Biometric and proximity sensor compatible protective case for mobile device

ABSTRACT

A protective case can be used with a mobile device having front and back surfaces and side surfaces extending between the front and back surfaces, including a top side, a bottom side, a right side, and a left side, the mobile device having a screen on the front surface. The protective case can include a shell configured to engage and substantially surround at least three of the surfaces of the mobile device and preferably all or nearly all surfaces of the mobile device while still capable of allowing the user to functionally interact with biometric sensor (such as a fingerprint sensor) and/or not interfere with the intended functionality of the proximity sensors of the mobile device.

INCORPORATION BY REFERENCE TO RELATED APPLICATIONS

This application claims benefit under 35 U.S.C. §119(e) from U.S.Provisional Application No. 61/785,755, filed on Mar. 14, 2013; U.S.Provisional Application No. 61/813,577, filed on Apr. 25, 2013; and U.S.Provisional Application No. 61/876,225, filed on Sep. 10, 2013. Thedisclosures of each of the applications cited in this paragraph areincorporated herein by reference in their entireties.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This patent document relates to protective cases for mobile devices.

2. Description of the Related Art

Mobile devices are known to sustain damage from impact, such as from afall or being dropped by a user and from contamination, such as whendamaged by water or other fluid. The damage, for example, may result ina cracked screen, scratches on a finished surface, lost or damagedbuttons or controls, cracked or bent external body components, and/orfailed or malfunctioning electrical components. Cases have thus beenprovided to protect mobile devices from such and variant types ofdamage.

Biometric sensors, such as fingerprint sensors, are increasingly beingused as a security measure to verify the identity of the user prior tofacilitating access or unlocking computing devices including mobiledevices. In addition, mobile devices are increasingly being equippedwith proximity sensors for detecting the presence of nearby objects,such as a face or pocket, etc. Conventional proximity sensors operatewithout need of any physical contact with the object, such that when themobile device is placed in close proximity to a user or put into apocket, the proximity sensor is triggered and the screen of the mobiledevice is automatically turned off to save power and/or to preventunintended operation of the touch interface of the screen by, forexample, the face or ear of the user or other objects.

Accordingly, there is a need for protective cases for mobile devicesthat are capable of not only providing suitable impact protection andprotection from the environment such as from moisture and debris, butthat are also capable of interfacing with biometric sensors employed bysuch devices. There is also a need for protective cases that are capableof not interfering with the desired functionality of proximity sensorsof such devices.

SUMMARY OF THE INVENTION

There exists a continuing need for new and improved designs for casesfor mobile devices that are compatible with biometric sensors and/orproximity sensors employed in such devices.

In one aspect, a protective case is disclosed that includes a userinterface that is capable of functionally interfacing with a biometricsensor such as a fingerprint sensor of the mobile device. The userinterface of the protective case includes a metallic or conductiveelement that corresponds in shape (in whole or in part) and is inproximate contact with an electrode element of the fingerprint sensor.The user interface may also include a dielectric element (e.g., anon-metallic or non-conductive material) that is interposed within, oradjacent to, the metallic conductive element and configured to resideabove an array of capacitive plates that comprise the sensing mechanismor circuitry of the fingerprint sensor. The conductive element of theuser interface may be printed or otherwise, applied, inked or layered onopposing sides of a substrate such as the dielectric element. Thefingerprint sensor user interface is incorporated within a protectivecase that is configured to be removable by the user. In oneimplementation the user interface is attached to a light-transmissivepanel that is configured to cover the front face and touch screen of themobile device. Various and numerous aspects of the biometric compatiblecase, including its configuration and construction, are apparent fromthe various embodiments described and illustrated herein. Methods of useof the biometric case that are capable of conditioning the biometricsensor with the protective case thereon to improve functionalreliability of the sensor when the device is enclosed within theprotective case are also disclosed.

Yet other aspects disclosed herein relate to the construction of aprotective case that is capable of avoiding unintended triggering ofproximity sensors of the mobile device for which the case is configuredto contain and protect. Various embodiments are disclosed including theuse of polarizing elements and light absorbing elements positioned over,between, and/or around the circumference of the proximity sensors. Thoseelements function to pass directional light and/or absorb light emittedby the proximity sensor so as to limit undesirable or unintendedtriggering of the proximity sensors by light reflected by the case backto the underlying sensor.

The foregoing various aspects and embodiments of the protective casessummarized above, as well as those disclosed herein, may be combined inany way without limitation.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages are described belowwith reference to the drawings, which are intended to illustrate but notto limit the invention. In the drawings, like reference charactersdenote corresponding features consistently throughout similarembodiments.

FIGS. 1A-B are front and back perspective views of an embodiment of aprotective case for a mobile device containing the mobile device.

FIG. 2A shows a partially disassembled front view of the protective caseof FIG. 1 and a mobile device.

FIG. 2B shows a partially disassembled back view of the protective caseof FIG. 1 and a mobile device.

FIG. 3 shows the first and second caps in a closed position of theprotective case of FIG. 1.

FIGS. 4A-B illustrate the components of the middle frame of theprotective case of FIG. 1.

FIG. 5 is a perspective interior view of an embodiment of a front plateof the base unit of FIG. 1.

FIG. 6 is an exploded view of the front plate of FIG. 5.

FIG. 7 is a partial exploded view of the protective case of FIG. 1without the front plate.

FIG. 8 is an exploded view of the back plate of the protective case ofFIG. 1.

FIG. 9 is a sectional view of the protective case and mobile device ofFIG. 1A taken along line A-A.

FIG. 10 shows a partial perspective side cross-sectional view of anembodiment of a protective case for a mobile device like the onegenerally depicted in FIGS. 1-9 wherein the case contains the mobiledevice. In this embodiment the protective case includes a fingerprintsensor user interface having a conductive element that is configured tointerface with the electrode element of a fingerprint sensor, such asthat depicted in FIG. 18, and is capable of functionally interfacingwith such sensor.

FIG. 11 is a more detailed cross-sectional view of the protective caseand mobile device of FIG. 10.

FIG. 12 shows a cross-sectional view of another embodiment of thefingerprint sensor user interface that includes a dielectric protectiveelement configured to reside over the electrical sensing elements of thefingerprint sensor of the electronic device for which the protectivecase is adapted or otherwise configured for use.

FIG. 13 shows a cross-sectional view of the fingerprint sensor userinterface depicted in FIG. 12, wherein the dielectric protective elementis in a stressed state, such as when depressed by the user to engage theunderlying home button of the device.

FIG. 14 shows a cross-sectional view of yet another embodiment of afingerprint sensor user interface that includes a dielectric protectiveelement such as that described in connection with FIGS. 12-13, which issupported in a threaded housing built into the conductive element thatinterfaces with the electrode element of the a fingerprint sensor.

FIG. 15 shows a sectional view illustrating the operation of proximitysensors of a mobile device enclosed within a protective case having aninternal surface that resides above and is spaced apart from theproximity sensors.

FIG. 16 shows a sectional view illustrating proximity sensors of amobile device with a protective case illustrated in FIG. 15, thatincludes an internally positioned polarizing element configured toreside above one or more of the proximity sensors to polarize the lightbeing transmitted therefrom.

FIG. 17 shows a sectional view illustrating proximity sensors of amobile device with a protective case illustrated in FIG. 15, thatincludes an internal positioned non-passing or light absorbing region orelement configured to reside above one or more of the proximity sensorsto isolate and/or absorb light that may interfere with the desiredfunctionality.

FIG. 18 is an illustration of a mobile device, such as that illustratedin FIGS. 2A-2B, with a fingerprint sensor incorporated into the homebutton.

FIG. 19 shows a top view of another embodiment of a protective case fora mobile device like the one generally depicted in FIGS. 1-9. In thisembodiment, like the embodiment depicted in FIG. 10, the protective caseincludes a fingerprint sensor user interface having a conductive elementthat is configured to interface with the electrode element of afingerprint sensor, such as that depicted in FIG. 18, and is capable offunctionally interfacing with such sensor. The conductive element isprinted or otherwise, applied, inked or layered on opposing sides of asubstrate element that overlies the fingerprint sensor. To betterillustrate the fingerprint sensor user interface, the protective case,like the one illustrated in FIG. 10, is depicted without the second capassembly described in connection with the protective case illustrated inFIGS. 1-9.

FIG. 20 is a more detailed top view of the lower region of theprotective case containing the fingerprint sensor user interfaceillustrated in FIG. 19. The shaded region is the conductive element ofthe fingerprint sensor user interface that resides below thelight-transmissive panel overlying the cell phone screen and extendsacross the home button aperture contained therein.

FIG. 21 is an exploded perspective view of the lower region of theprotective case illustrated in FIGS. 19-20. Various components of thelower region of the protective case and the fingerprint sensor userinterface incorporated therein are illustrated.

FIG. 22 is an exploded perspective view of the conductive and substrateelements of the fingerprint sensor user interface of the protective caseillustrated in FIGS. 19-21. An example of a lay-up of the conductive andsubstrate elements of the fingerprint sensor user interface includingthe layers of conductive ink on opposing sides of a polymer substrate isillustrated. The opposing conductive ink layers are in physical and/orelectrical contact with each other. Each conductive ink layer includes aprimary region that is configured to reside above the electrode elementof a fingerprint sensor and one or more secondary regions, illustratedin the form of projections extending radially outward from the primaryregion.

FIG. 23A is an illustration of an alternative conductive inkconfiguration for the fingerprint sensor user interface illustrated inFIGS. 19-22, wherein the conductive ink element includes a primaryregion that is configured to reside above the electrode element of afingerprint sensor and multiple secondary regions in the form ofprojections that extend on either side of the primary region radiallyoutward therefrom. As in the case of the fingerprint sensor userinterface depicted in FIG. 22, the opposing conductive ink layers are inphysical and/or electrical contact with each other and are positioned oneither side of a substrate sheet.

FIG. 23B is an exploded view of the substrate and the opposing layers ofthe conductive ink element of the alternative conductive inkconfiguration illustrated in FIG. 23A.

FIG. 24A is an illustration of another alternative conductive inkconfiguration for the fingerprint sensor user interface illustrated inFIGS. 19-22, wherein the conductive ink element includes a primaryregion that is configured to reside above the electrode element of afingerprint sensor and a secondary region in the form of singleprojections that extends downward and radially outward from the primaryregion. As in the case of the fingerprint sensor user interface depictedin FIG. 22, the opposing conductive ink layers are in physical and/orelectrical contact with each other and are positioned on either side ofa substrate sheet.

FIG. 24B is an exploded view of the substrate and the opposing layers ofthe conductive ink element of the alternative conductive inkconfiguration illustrated in FIG. 24A.

FIG. 25 is a partial exploded view of a modified embodiment of theprotective case such as that illustrated in FIGS. 19-24, wherein theconductive element of the fingerprint sensor user interface is comprisedof a first component that is printed or otherwise, applied, inked orlayered on opposing sides of a substrate element such as that depictedin FIGS. 19-24 and a second electrically conductive component (such asthe conductive elements depicted in FIGS. 10-14), which is positioned tooverly and be in physical contact and/or electrical communication withthe upper surface of the first component of the conductive element.

FIG. 26 is flow chart reciting selective steps for a process for makinga protective case for a biometric secured mobile device includes abiometric sensor user interface such as those described herein.

FIG. 27 is a partially exploded perspective view of the top region ofthe protective case illustrated in FIG. 19 providing a more detailedview of a polarizing element configured to reside within the case abovethe proximity sensor of the mobile device for which the case isconfigured to receive. More specifically, the polarizing element iscontained within a compartment that is defined by an enlarged speakeraperture contained within a light-transmissive panel above alight-transmissive laminate that overlies the inner surface of thelight-transmissive panel in a region above the proximity sensor.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Disclosed herein are embodiments of a protective case for a mobiledevice configured to maintain substantial functionality of the mobiledevice while both reducing the likelihood of damage to the device due toshocks and other forces sustained by the device and reducing thelikelihood of ingress of liquids (such as water), dust, or debris intothe protective case when in a fully closed configuration. Theembodiments disclosed herein are described in the context of a mobiledevice case for a cell phone because the embodiments disclosed hereinhave particular utility in this context. However, the embodiments andinventions herein can also be applied to other types of mobile devicessuch as, but not limited to, tablets (such as an iPad®), PDAs,e-readers, mp3 players (such as an iPod®), portable gaming devices, andother mobile devices of similar nature. Further, while the embodimentsdisclosed herein are tailored to correspond with the dimensions andfeatures of the mobile device depicted for which the case is configuredto receive, it should be understood that the teachings herein areapplicable and transferrable to cases configured to receive other mobileand electronic devices.

FIGS. 1-3 are illustrations of an embodiment of a protective case 10 fora mobile device 20. The case 10 can be generally shaped to contain andprotect a mobile device (e.g. an iPhone®). When placed inside of a case,the mobile device desirably fits snugly, although the user desirablystill has access to the buttons and/or touch screen of the mobile deviceeither directly through apertures in the case 10 or indirectly throughother features of the case. In some embodiments, the protective case 10is configured to reduce or prevent the ingress of undesirable fluids(such as water), dust, or debris into the protective case 10 and ontosensitive components of the mobile device 20 which may be inserted intothe protective case 10. In some embodiments, the case is waterproof whenin an assembled state.

As best seen in FIGS. 2A-B, the mobile device may have a front surface22 with a screen located thereon, a back surface 24, and side surfacesextending between the front and back surfaces 22, 24, including a topside 26, a bottom side 32, a right side 30 (as viewed from the displayscreen 22), and a left side 28. The protective case 10 may include atleast two components—a shell 40 which may serve as the primaryprotection mechanism for the case such that it engages and substantiallysurrounds multiple surfaces of the mobile device 20 and cap assemblieswhich may reversibly attach (i.e., engage and disengage) to the shell40. A cap assembly may provide additional protection for apertures inthe shell 40. For example, a first cap assembly 60 having a first cap 64may be attached to a first hinge 62, which may be reversibly attached tothe shell 40 to prevent or allow access to portions of the shell 40and/or mobile device (FIG. 1). Additionally, in some embodiments, theprotective case 10 may include a second cap assembly 80 having a secondcap 84 attached to a second hinge 82 which may be reversibly attached tothe shell 40 to prevent or allow access to portions of the shell 40and/or mobile device 20.

As such, as shown in FIG. 1A, when fully assembled the shell 40 of theprotective case 10 can engage and substantially surround multiplesurfaces of the mobile device 20 to both reduce the likelihood ofingress of fluid into the protective case as well as to provideadditional protection to the mobile device 20 from shocks and otherpotentially harmful forces sustained by the device. In the illustratedembodiment, the shell 40 can engage and substantially surround themobile device. For example, the shell 40 may engage and substantiallysurround at least five surfaces of the mobile device.

The shell 40 may itself include two or more components such as a baseunit 100 and a back plate 200 as best seen in FIGS. 2A-B. The base unit100 and back plate 200 may be removably attached from one another, suchas by snap fit, to allow the insertion and removal of the mobile device20 from the protective case 10. In FIGS. 2A-B, the two components of theshell 40—the base unit 100 and the back plate 200—are shown detachedfrom each other. The base unit 100 may include the primary supportstructure for the protective case 10 and therefore engage andsubstantially surround a majority of the surfaces of the mobile device,such as surfaces 22, 26, 28, and 30 of the mobile device 20. Since thebase unit 100 preferably can engage and substantially surround the frontsurface 22 of the mobile device 20, the base unit 100 can include apanel 130 to allow a user of the protective case 10 to view contentspresented on the screen of the front surface 22. The panel 130 can belight-transmissive and may also allow a user to communicate with a touchscreen on the device. The back plate 200, when attached to the base unit100, is configured to provide a seal for the shell 40 such that fluidingress is reduced or prevented through the back plate 200.

Components of the base unit 100 and back plate 200 may be co-molded fromtwo or more different materials. In some embodiments, the base unit 100may be manufactured from two materials. The first material may exhibitat least a slight degree of flexibility and may include polymers suchas, but not limited to, thermoplastic polyurethane. The second materialmay exhibit greater rigidity than the first material and may includepolymers such as, but not limited to, polycarbonates. This co-molding oftwo or more different materials allows for enhanced functionalcharacteristics of the base unit 100 without sacrificing protectionagainst ingress of undesirable fluids. As will be discussed in furtherdetail below, the first material may be used for features of the baseunit 100 requiring deformability or flexibility such as buttons and/orhinges. The second material may be used for purely structural componentsof the base unit 100 such as the frame and plates.

The base unit 100 may include one or more apertures along any side ofthe base unit 100. The one or more apertures can be configured to allowpassage of connection members such as data cable, power cables,headphone jacks, from outside the shell 40 and into the appropriateconnectors, jacks, or ports on the mobile device 20. Such apertures mayalso be configured to allow passage of fluids such as air while reducingor preventing passage of liquids such as water by usingselectively-permeable seals. The shell 40 may include any numberapertures corresponding to the location of connectors, jacks or ports onthe mobile device 20. The illustrated mobile device of FIG. 2A has aheadphone jack 34, a microphone 35, a data connector 36, and a speaker37 along the bottom side surface 32. The shell 40 may have acorresponding headphone aperture 44, microphone aperture 45, dataaperture 46, and speaker aperture 47 along a bottom portion of the shell40.

A cap assembly can be used to cover one or more apertures on the shell40. A cap assembly may also be used to provide a sealing mechanism forthe shell 40 which reduces or prevents the ingress of fluids, dust, ordebris into the shell 40. The cap assembly may be free standing or maybe attached to the shell 40, such as through a hinge. In addition, thecap assembly can be configured to cover the aperture in one of manydifferent ways. For example, the cap assembly may engage the aperturedirectly, such as through a friction fit between the cap assembly andthe aperture. In other embodiments, the cap assembly may connect to theshell outside of the aperture and may surround the aperture while notdirectly contacting the aperture.

In some embodiments, the hinge can be an integral of a co-molded shellcomponent having a first material more flexible than the secondmaterial. The first material can be used to form the hinge. The flexiblematerial can be sufficiently flexible to allow the hinge and capassembly to move between two positions, such as an open and closedposition.

A first cap assembly 60 may be comprised of a first hinge 62 and a firstcap 64 to cover an aperture located on the shell 40 (FIG. 1A). First capassembly 60 may be used to provide an additional sealing mechanism forthe shell 40 which reduces or prevents the ingress of fluids, dust, ordebris into the shell 40. First hinge 62 may be a living hinge formingan integral unit with the shell 40, such as the body 160. In someembodiments, the first hinge 62 is formed of a first, flexible material.The flexible material may be one of two materials where one or morecomponents of the shell 40 are formed of two materials, such as beingco-molded.

As illustrated in FIG. 2A, two potential embodiments of a first cap, 64and 64 a, are shown which can be attached to the hinge 62. The first capcan attach to the hinge in one of many different ways. First caps 64 and64 a may have annular slots 66 and 66 a configured to be received withinan aperture 68 on hinge 62. FIGS. 1A-B show the first cap 64 mounted onthe hinge 62. The first cap may also or alternatively be glued or weldedto the hinge. As shown, first cap 64 a has an additional insertionmember 65 which may be configured to be received within a connector,jack or port on the phone. In some embodiments, first caps 64 and 64 amay be manufactured from different materials which provide moreadvantageous sealing characteristics such as silicone rubber. In someembodiments, the first cap may be formed with the hinge and may be thesame material.

First cap 64 may be retained within the shell 40 via a press fit,friction fit, or interference fit as a result of the elasticity of thematerial used. In some embodiments, the first cap 64 may be configuredto engage and disengage an aperture on the shell 40, such as theheadphone aperture 44, the microphone aperture 45, the data aperture 46,or the speaker aperture 47. In such embodiments, the first cap 64 coversan associated connector, jack or port 34, 35, 36, or 37 on the mobiledevice 20. In some embodiments, the first cap 64 may both cover andengage connectors, jacks or ports on the mobile device 20 such as theheadphone jack 34, the microphone 35, the data port 36, or the speaker37 (FIG. 2A). In the illustrated embodiment, the first cap 64 isconfigured to be reversibly attached to the headphone aperture 44thereby covering the headphone jack 34 of the mobile device 20. In someembodiments, the first cap 64 may be used to cover and/or engage one ormore ports on the mobile device such as a headphone jack, a powerconnector, a data connector, speaker, microphone, or any other port on amobile device.

The protective case 10 may include one or more additional capassemblies. As shown in FIG. 2A, a second cap assembly 80 may becomprised of a second hinge 82 and a second cap 84 to cover apertureslocated on the shell 40. Second cap assembly 80 may also be used toprovide an additional sealing mechanism for the shell 40 which reducesthe likelihood, or prevents, ingress of fluids, dust, or debris into theshell 40. Second hinge 82 may be a living hinge forming an integral unitwith the shell 40. In some embodiments, the second hinge 82 is formed ofa first, flexible material. The flexible material may be one of twomaterials where one or more components of the shell 40 are formed of twomaterials, such as being co-molded. Second cap 84 may be attached to thesecond hinge 82 via attachment mechanisms such as a press fit,co-molding, adhesive, ultrasonic welding, or any other attachmentmechanism known in the art. In some embodiments, second cap 84 may bemanufactured from materials providing greater rigidity such aspolycarbonates. In some embodiments, the second cap 84 may bemanufactured from the same material as the first or second material ofthe shell.

The second cap 84 may removably attach to the shell 40 or an aperture onthe shell via a friction fit, snap fit, or any other attachmentmechanism known in the art. In reviewing FIGS. 1A-B and 3, it can beseen that the second cap 84 can engage and attach to the front plate 120and the back plate 200 of the shell 40. Thus, the second cap 84 can belarger than the end of the shell and the bottom of the shell, and mayfit over the end. The front plate 120 and/or back plate 200 can includeone or more dimples 48 (FIG. 1A). The second cap 84 can have acorresponding one or more small protrusions 50 (FIG. 1B) that can fit inthe one or more dimples 48. When a dimple 48 and protrusion 50 are movedto an engaged position the user may hear an audible click or snap. Thiscan indicate to the user that the second cap 84 is properly closed. Itwill be understood that in some embodiments, the dimple is on the secondcap 84 and the protrusion is on the shell 40.

Second cap 84 may additionally include apertures along its surface toallow access to the associated apertures or features on the shell 40and/or mobile device. In some embodiments, the second cap 84 may includea headphone aperture 94, a microphone aperture 95, and a speakeraperture 97. The second cap 84 may include additional apertures forapertures on the shell 40 allowing access to power connectors, dataconnectors, and any other connector located on the mobile device 20. Thesecond cap 80 may also include gaskets configured to provide additionalseals for apertures located on the shell 40. As such, second cap 80 maybe configured to cover connectors, jacks and/or ports such as headphonejacks, power connectors, data connectors, speakers, and microphones onthe mobile device 20.

In some embodiments, a protective case for a mobile device can comprisea shell configured to engage and substantially surround at least threesurfaces of the mobile device. The shell can comprise a first materialco-molded with a second material, the first material being flexible andthe second material being harder than the first material. A first capcan be configured to engage and disengage with the shell to therebyprevent or allow access to a portion of the mobile device. A first hingecan extend from the shell and connect the first cap and the shell. Thefirst hinge can comprise the first material and be configured to permitthe first cap to move between an engaged position and a disengagedposition with the shell. The first cap can be configured to cover atleast one of a headphone jack, a power connector, a data connector,speaker, and a microphone on the mobile device.

The protective case can also include a second cap configured to engageand disengage with the shell to thereby prevent or allow access to aportion of the mobile device. The second cap can be connected to theshell via a second hinge extending from the shell. The second hinge canbe made of the first material and be configured to permit the second capto move between an engaged position and a disengaged position with theshell.

In some embodiments, a protective case for a mobile device can include ashell configured to engage and substantially surround at least two,three, four, five, or six of the surfaces of the mobile device. Theshell can comprise a first headphone jack hole configured to allow aheadphone connector to pass through the shell and connect to a headphonejack on the mobile device. A headphone jack cover can move between anengaged position and a disengaged position wherein the headphone jackcover is respectively engaged or disengaged with the shell at theheadphone jack hole to thereby prevent or allow access to the firstheadphone jack hole. A cap can be configured to move between an engagedposition and a disengaged position wherein the cap is respectivelyengaged or disengaged with the shell wherein the cap is also configuredsuch that when the headphone jack cover is in its engaged position,movement of the cap between its engaged and disengaged position the capalso engages and disengages with the headphone jack cover. The cap cancomprise a second headphone jack hole configured to allow a headphoneconnector to pass through the cap to the first headphone jack hole andto connect to a headphone jack on the mobile device when the headphonejack cover is in its disengaged position and the cap is in its engagedposition.

In a fully closed or engaged position, the first cap 64 may be engagedwith an aperture 44 on the shell 40. Second cap assembly 80 may then beengaged with the shell 40 and with the first cap 64 a, 64 b. As anon-limiting example, the first cap 64 may be engaged to both theheadphone aperture 44 of the shell 40 and the headphone aperture 94 ofthe second cap 80, as can partially be seen in FIG. 3.

This feature of having the first cap 64 under the second cap 80 canprovide a beneficial an extra safety feature. In some embodiments, theprotective case 10 may also have “fail-safe” functionalities to ensurethat a user is aware of whether or not the protective case 10 is fullyprotected against unwanted ingress or not. In some embodiments, thesecond cap assembly 80 may be configured to be incapable of properlyengaging the shell 40 in a closed position if the first cap assembly 60is neither in a fully closed nor in a fully open position with respectto the shell 40. As such, the second cap assembly 80 may be preventedfrom engaging the shell 40 when the first cap assembly 60 is improperlyengaged with or misaligned within an aperture on the shell 40. This“fail-safe” mechanism reduces the likelihood that a user of theprotective case 10 will unknowingly improperly close the protective case10 and potentially cause damage to the mobile device 20 due to ingressof liquids, dust, or debris.

For example, in some embodiments, when the second cap assembly 80engages with the shell 40 in a closed position, the user can hear anaudible click or snap. In some embodiments, the user may be able tovisually see that the second cap is closed because, for example, itsposition matches or is parallel to features on the shell itself. Whenthe first cap 64 is close to its closed position, but not properlyengaged with the shell and/or aperture, the second cap can be preventedfrom closing. This may mean that the user will not hear the audibleclick, or that the second cap will not be aligned with features on theshell. This, the user can know that the second cap is not properlyclosed.

Having hinged caps also provides the benefit of maintaining the caps onthe case. Thus, they cannot be lost unless they are broken off the caseitself. The hinges may also allow the caps to be moved fully out of theway when not in use.

In some embodiments, the first cap can be in an open position while thesecond cap is in the closed position. This can allow a user to connect apair of headphones or a headset to the mobile device without removingthe mobile device from the case. In some embodiments, the headphone jackcan engage the case in such a way to maintain the case in a sealed orsubstantially sealed condition.

As shown in both FIGS. 2 and 3, which are perspective views of theprotective case 10, the shell 40 may be comprised of both a base unit100 and a back plate 200. The base unit 100 and the back plate 200 maybe configured such that they may be reversibly attached from each other.In such arrangements, the mobile device 20 may be inserted into eitherthe base unit 100 or the back plate 200 while the two components of theshell 40 are separated.

The shell 40 may include features which allow the mobile device 20 to besuspended or partially suspended within the case. As has been mentioned,the shell, including the base unit 100, may be formed of two materials,such as by co-molding. In some embodiments, a suspension system can beco-molded into the case. For example, the base unit 100 may suspend thesides of mobile device. The softer material can be formed into ribswithin the shell configured to suspend the mobile device within the case10. As another example, as will be discussed in more detail below withrespect to FIGS. 8-10, the back plate 200 may have raised sides 204 onthe surface 206 facing the mobile device. Thus, the back of the mobiledevice may be substantially suspended from the rest of the back plate200.

With reference to FIGS. 2A-B the base unit 100 is shown with a middleframe 160 that has been co-molded of two separate materials 180, 162.The first material 180 may exhibit at least a slight degree offlexibility and may include polymers such as, but not limited to,thermoplastic polyurethane. The second material 162 may exhibit greaterrigidity than the first material 180 and may include polymers such as,but not limited to, polycarbonates. The first material 180 may be usedfor features of the base unit 100 requiring deformability or flexibilitysuch as buttons and/or hinges and may be sufficiently flexible to allowmovement between two or more positions. The second material 162 mayprovide the base structural support. The second material can besufficiently hard to protect the mobile device from impact, such asdrops and strikes. For example, the harder material should be able towithstand and protect the mobile device from being hit against a sharpedge or corner of a table, as well as, from being dropped by a user. Ashas been discussed, the first and second hinges 62, 82 may be formed ofthe first, flexible material 180.

Turning now to FIGS. 4A-B, the middle frame 160 is shown. In FIG. 4A themiddle frame is shown as it could appear after the co-molding processwith both materials 162, 180 joined together to form the middle frame160. FIG. 4B is for illustration purposes only and shows the twomaterials separately. It should be understood that the middle frame 160would not exist as two separate components. Rather, typically the secondharder material 162 would be molded into the desired shape, such as byinjection molding and then the first material would be molded into andonto the second material, such as by over molding, to form the co-moldedmiddle frame 160. Thus, the co-molded material can be a unitary orsingle unit that does not separate under normal conditions.

The second material can form a body 162. The body 162 may be configuredto provide structural support for the shell 40. The body 162 may bemanufactured from materials that may exhibit greater rigidity than othermaterials used on the device and may include polymers, such as, but notlimited to, polycarbonates, as well as other similar materials.

The body 162 may include a number of apertures that may correspond tofeatures such as connectors, jacks, buttons or ports on the mobiledevice 20. These apertures may be provided to allow access to thefeature in the assemble case 10, or these apertures can be configured toreceive the first material 180. As the first material 180 is moreflexible than the second material, it can advantageously be used to formbuttons, seals, hinges, etc. For example, the body 162 may include avolume/mute aperture 166 along one side of the body. The body 162 mayalso include one or more channel 156 and/or channel 158 configured toreceive the first material 180. The body 162 may additionally includeretention receivers 168 configured to receive an attachment mechanismlocated on the back plate 200.

As has been mentioned, the first material 180 can be different from andmore flexible than the second material used for the base 162. In someembodiments, the first material 180 may be manufactured from materialsexhibiting a greater degree of flexibility compared to other materialsused for the shell 40. This may include polymers such as, but notlimited to, thermoplastic polyurethane, as well as other similarmaterials. The first material can be co-molded with the body 162 to formthe middle frame 160.

As illustrated, the first material 180 is formed as a continuouselongate strip. It will be understood that the first material 180 couldbe attached to the base at one or more discreet locations that are notconnected. For example, the first material 180 can be co-molded with themiddle frame 160 in three different parts, corresponding with the topand two sides of the middle frame 160. Having the hinges 62, 82 attachedto a larger piece of material can beneficially increase the life of thehinges. It will be understood that the hinges will likely see a lot ofuse and so having the hinges on a larger piece of material co-molded tothe body 162 can help prevent pealing, premature breakage, and/orseparation of the hinge from the body 162.

As shown, the first material 180 includes first hinge 62 and secondhinge 82. In some embodiments, second hinge 82 has an attachment strip83 that can be used to attach to the second cap 84. In such embodiments,the second cap 84 may be attached to the second hinge 82 by placing theelongate strip 83 within the second cap 84. The attachment strip 83 canbe shaped and dimensioned to correspond to the second cap 84.

The first material 180 may also be used to form buttons and/or rockerson the middle frame 160. The buttons and/or rockers can allow a user toactivate switches located on the mobile device such as a power switches,volume switches, mute switches, hold switches, lock switches, and othersimilar types of switches used on a device. As such, the first materialmay form a power button 186, volume buttons 188, and a mute rockerswitch 192. In some embodiments, one or more button or switch can belocated on a button panel 190.

The first material 180 may also form internal ribs 184 which may beconfigured protrude within the body 160. The internal ribs 184 can beused to suspend the mobile device 20 from the body 162 when a mobiledevice 20 is placed within the case.

The internal ribs 184 can be vertically extending thin bands when thecase is laying face down as shown in FIGS. 4A-B. The internal ribs 184can be placed on one or more internal sides of the middle frame 160. Forexample, as shown the internal ribs are positioned around the top andthe two sides. The internal ribs 184 may correspond in thickness to thechannels 156. The channels for the internal ribs 184 can be thin groovesin the second material 180. The internal ribs 184 can be grouped inpairs or threesomes. In addition, the internal ribs 184 may extend fromother parts of the first material. For example, the internal ribs 184may extend from a button, switch or a button panel 190. As shown, aninternal rib 184 extends from either side of the button panel 190.

The internal ribs 184 have a height, width, and depth. In someembodiments, the height can be measured as extending from the front face120 to the back 200. The depth can be measured as extending inward fromthe body 162 towards the interior volume. The width can be measuredalong the body 162, for example from the top to the bottom or from sideto side, depending on where the internal rib is located. In someembodiments the height of the internal ribs is at least 80 percent ofthe distance between the front edge and back edge of the body 162. Insome embodiments, the width of the internal ribs is smaller than theirheight.

In some embodiments, a protective case can include a plurality ofinternal ribs along an internal surface of the case. The internalsurface can surround at least the top, bottom and two sides of themobile device. The ribs can be preferably be located on at least threeof the surfaces, such as along the top and the two sides. The ribs maybe the furthest inward projecting structures along those surfaces thatcontact the mobile device apart from buttons or switches on the case.These ribs can be substantially thin as compared to their height. Forexample, they can have a width less than ½, ⅓, ¼, or even smaller thantheir height.

As the case can be configured to be tight fitting, a plurality of thinribs can beneficially suspend the mobile device within the case tobetter protect the mobile device, but can also provide many locations tobe able to engage the mobile device with one's fingers to remove themobile device from the case. In many current devices that offer somedegree of water protection, it can be extremely difficult to remove themobile device from the case. If there is cushioning in the case, it isoften large blocks of cushioning which may provide certain benefits butcan make removal of the mobile device very difficult. In addition toproviding many locations for the fingers to engage the mobile device theplurality of ribs can also prevent sticking and/or capillary action thatmay otherwise occur within a watertight case that may make removal ofthe mobile device difficult.

Returning now to FIGS. 1A-2B, it can be seen that a front plate 120,including the panel 130 can be connected to the middle frame 160. Thefront plate 120 can be attached to the middle frame 160 using variousattachment mechanisms such as adhesives, welding, or any otherattachment mechanism known in the art. In one example, middle frame 160is ultrasonically welded to the front plate 120. FIGS. 5-6 show furtherdetails of the front plate 120.

The front plate 120 may be comprised of multiple components including afront frame 122 and in some embodiments a panel 130, such as alight-transmissive panel. The outermost (i.e., front-most) component maybe a front frame 122 having apertures corresponding to functionalcomponents, speakers, microphones, cameras, screen (LCD screen, touchscreen, etc.), connectors, ports, or jacks on the front surface 22 ofthe mobile device 20. As shown in FIG. 6, the front frame 122 has amicrophone aperture 121, a speaker aperture 124, a camera aperture 125,a button aperture 126, and a screen aperture 127. Other apertures may beincluded depending upon the mobile device 20. Such apertures may beincluded to provide access to these functional components, connectors,ports or jacks while the mobile device 20 is engaged and with the frontplate 120. The front panel 122 may additionally include raisedprotrusions 128 which extend from the front plate 122 in perpendicularto the front surface. Such protrusions 128 may be configured to contactand abut the middle frame 160 of the base unit 100 when fully attached.

As the front frame 122 may be configured to provide structural supportfor the shell 40 and the attached components of the front plate 120, thefront frame 122 may be manufactured from materials that exhibit greaterrigidity than certain other materials used on the device and may includepolymers, such as, but not limited to, polycarbonates, as well as othermaterials such as metals and rubbers with a high shore rating.

The front plate 120 may include a panel 130, such as alight-transmissive panel which includes apertures for functionalcomponents, speakers, microphones, cameras, connectors, ports, or jackson the front surface 22 of the mobile device 20 such as a speakeraperture 132 and a button aperture 134. Other apertures may be includeddepending on the mobile device 20. Such apertures may be included toprovide access to these functional components, connectors, ports orjacks while the mobile device 20 is engaged and with the front plate120. The light-transmissive panel 130 may additionally include a panelgasket 136 located around its perimeter edges to provide a moreadvantageous seal against the ingress of fluid, such as water, into thefront plate 120. As such, panel gasket 136 may be made of materialsproviding advantageous sealing characteristics such as rubbers with alow shore rating and silicone rubber.

Light-transmissive panel 130 may be dimensioned to snugly fit within thefront frame 122 and may be manufactured of any type oflight-transmissive material such as glasses or plastics. Additionally,in some embodiments, the material may also be electrically conductivesuch that the functionality of a touch screen, such as resistive orcapacitive touch screens, would not be substantially affected. In someembodiments, the light-transmissive panel 130 may be made of temperedglass. The light-transmissive panel 130 may be attached to the frontframe 122 via an adhesive 138, by welding, or any other attachmentmechanism known in the art.

Preferably, the panel 130 is made of glass. Having a glass panel canprovide the case 10 with many benefits. For example, glass is much moreresistant to scratching than is plastic. In addition, glass generallydoes not create bubbles or create distortion in ways that plastic might.Still further, glass is also not as susceptible to deterioration,fading, discoloration as many plastics. Glass can be made very thin andcan also be extremely strong.

Front plate 120 may include a button 144 configured to fit within buttonapertures 126 and 134 of the front plate 120 and the light-transmissivepanel 130 respectively. The button 144 may be made of materials havingadvantageous sealing characteristics while also being relativelydeformable. Such materials may include soft polymers such as rubber witha low shore hardness and softer plastics. In some embodiments, thebutton 144 may be made of materials such as silicone rubber. The buttonmay be attached directly to the front frame 122 via adhesives,overmolding, welding, or any other attachment mechanism known in theart.

Front plate 120 may additionally include suspension members 146 and 148which can be attached to an interior surface of the light-transmissivepanel 130 such that the front surface 22 of a mobile device 20 can beslightly elevated from the light-transmissive panel 130. Such elevationfrom the light-transmissive panel 130 may reduce the likelihood ofdamage to the front surface 22 based on reduced contact with the frontsurface 22. The amount of elevation may be chosen such that contact canstill be made between the light-transmissive panel 130 and the frontsurface 22 when pressure is applied to the light-transmissive panel 130.In some embodiments, the suspension members 146 and 148 can comprise afabric material such as felt.

Front plate 120 may also include one or more membranes that can be usedto seal off the front plate from unwanted liquid, dust, or debris whileallowing sound or other transmissions to pass through the membrane. Forexample, a selectively-permeable seal 140 with a gasket 142 can beconfigured to cover an aperture of the front plate 120. Theselectively-permeable seal 140 may be configured to either reduce orprevent the passage of certain fluids, such as water, through the seal.As such, the selectively-permeable seal 140 may advantageously protect amobile device 20 from ingress of harmful fluids such as water whileproviding relatively unhindered functionality for microphones andspeakers. Selectively-permeable seal 140 may be manufactured from anytype of material allowing for selective-permeability such as, but notlimited to, polyethylene terephthalate (PET), andpolytetrafluoroethylene (PTFE) or other fluoropolymer products such asGORE-TEX. In some embodiments, the materials used forselectively-permeable seal 140 may differ from materials used forselectively-permeable seals used on other parts of the shell 40.

In some embodiments, the selective-permeability seal 140 can comprise alayered membrane 140. In some embodiments the layered membrane seal 140can comprise a first layer of PTFE, a second layer being a PET spacerand a third layer of a metal mesh. In other embodiments the layeredmembrane 140 can comprise a first layer of PTFE and a second layer of anylon-like mesh.

The gasket 142 for the selectively permeable seal 140 may be placedbetween the seal 140 and the component upon which it is attached toprovide an additional sealing mechanism against fluid ingress. In someembodiments, the selectively-permeable seal 140 may be placed betweenthe front frame 122 and the light-transmissive panel 130 such that theselectively-permeable seal 140 covers the speaker apertures 124, 132.The seal 140 may also cover the microphone aperture 121. In someembodiments, because of the proximity of the speaker and microphone,only one seal may be needed in the vicinity of the speaker and/ormicrophone.

In some embodiments, the selective-permeability seal 140 can be aflexible membrane to not only allow the passage of sound, but also toadjust for pressure changes inside the case. It will be understood thatwhen the panel 130 is glass, and the rest of the shell is primarilyplastic, there may not be much room for the case, or the glass toexpand, or otherwise deal with pressure differences between the case andthe surroundings. The selective-permeability seal can be flexible toallow for expansion or movement of the seal as a way to deal with thepressure changes. In addition, the seal 140 and gasket 142 can also beformed to allow for compression and/or expansion of the gasket with theseal 140 to balance pressure differences. As, shown in FIG. 6, thegasket 142 can be received in a depression in the front frame 122 aroundthe aperture 124. The seal can be attached to the gasket and can beingcontact with the glass panel 130. One or more of the gasket and seal canmove, flex, expand, and/or compress as pressure differences areexperienced between the case and the atmosphere.

Moving now to FIG. 7, additional selectively-permeable seals or layeredmembranes are shown. The mobile device may include multiple speakersand/or microphones that may located at various locations on the device.Thus, the case can include apertures and membranes on any of itssurfaces to correspond to one or more of the speakers and/ormicrophones. In some embodiments the layered membranes may be the samefor all of the components, but they may also be different. For example alayered membrane for a speaker at the bottom of the case may bedifferent than a layered membrane for a speaker at the top of the case,similarly, for a microphone. In some embodiments, the layered membranecan be different depending on whether it is used for a speaker or amicrophone.

As shown in FIG. 7, the middle frame 160 (shown without the secondmaterial 180 for ease of illustration) may have apertures correspondingto connectors, ports, jacks, buttons, or any other functional componenton the exterior of the mobile device 20 which allow access to thesefunctional components. Middle frame 160 may also include aselectively-permeable seal 172 and gasket 173 configured to cover one ofthe apertures, such as a speaker aperture 47. Middle frame 160 may alsoinclude a selectively-permeable seal 174 and gasket 175 configured tocover a second one of the apertures, such as a microphone aperture 45.Such selectively-permeable seals 172 and 174 may be configured to eitherreduce or prevent the passage of certain fluids, such as water, throughthe seal while still allowing other fluids, such as air, to pass withlittle to no restriction through the seals 172 and 174. As such, theselectively-permeable seal 172 and 174 may advantageously protect amobile device 20 from ingress of harmful fluids, dust, or debris whileproviding relatively unhindered functionality for microphones andspeakers.

Selectively-permeable seals 172 and 174 may be manufactured from anytype of material allowing for selective-permeability such as, but notlimited to, polyethylene terephthalate (PET), andpolytetrafluoroethylene (PTFE) or other fluoropolymer products such asGORE-TEX. In some embodiments, the materials used forselectively-permeable seal may differ from materials used forselectively-permeable seals used on other parts of the shell 40. In someembodiments the selective-permeability seal is a layered membrane andcan comprise a first layer of PTFE, a second layer of a PET spacer and athird layer of a metal mesh. In other embodiments theselective-permeability seal 140 can comprise a first layer of PTFE and asecond layer of a nylon-like mesh. Seals 172, 174 and 140 may bemanufactured from different materials. In some embodiments, seals 172and 140, which are both used to cover speaker apertures, may bemanufactured from the same materials.

In some embodiments, the seal 172 for the speaker is made from a firstlayer of PTFE and a second layer of nylon like mesh and the seal 140 forthe speaker is made from a first layer of PTFE, a second layer of a PETspacer and a third layer of a metal mesh. In some embodiments, the seal174 for the microphone is made from a first layer of PTFE, a secondlayer of a PET spacer and a third layer of a metal mesh.

The back of the mobile device may include a speaker and/or microphone.Thus, the back plate 200 may also include one or moreselectively-permeable seals 218 as shown in FIG. 8. In some embodiments,the seal 218 for the microphone is made from a first layer of PTFE and asecond layer of nylon like mesh, though other materials can be used aswill be understood.

The back plate 200 may also include assemblies to allow access throughthe case of certain functional components located on a back surface ofthe mobile device 20. The back plate 200 may include a camera aperture212, a flash aperture 213, and a microphone aperture 211. It may alsoinclude a corresponding camera panel assembly 214. These apertures maybe sized and shaped to allow access to a camera, a flash component, anda microphone located on the back surface 24 of the mobile device. Thecamera panel assembly 214 may be comprised of a light-transmissive panel216, a selectively-permeable seal 218, a gasket 220, and adhesivematerial 222. The selectively-permeable seal 218 may be used to cover amicrophone located on the back surface 24 of the mobile device as hasbeen described.

According to some embodiments, the camera panel assembly 214 can beattached to the back plate 200 in the following order. Theselectively-permeable seal 218 can first be placed over the microphoneaperture 211. This can be followed by the adhesive and then thelight-transmissive panel 216 can be placed over all three apertures 211,212, 213. Finally a gasket 220 can be attached to the light-transmissivepanel 216.

The gasket 220 can engage with the back 24 of the mobile device. Byhaving a gasket around the microphone on the back of the mobile devicean echo can be prevented from occurring. Thus, the microphone can beacoustically isolated from the rest of the insides of the case. Forexample, the microphone can be acoustically isolated from sound from thespeakers on the mobile device that is being transmitted within the case.Of course, sound outside of the case, including from the speaker of themobile device may still reach the microphone.

In some embodiments, a protective case can include a hole passingthrough the case that is configured to be positioned near a microphoneof the mobile device. The case can include a gasket surrounding the holebeing raised from the inside surface of the case to engage the mobiledevice and to form a sealed enclosure around the hole to acousticallyisolate the sealed enclosure from the rest of the insides of the case.In some embodiments, the gasket 220 can be a rubber gasket. In someembodiments, a membrane can cover the hole.

In other embodiments, the gasket can be used to seal the case to preventthe inflow of liquid, dust or debris from entering the case, but canallow sound to travel through the gasket. For example, the gasket 220can be a relatively thin gasket. In some embodiments, the gasket can bemade of foam and can be substantially the same or only slight tallerthan the back surface.

The back plate 200 may have raised sides 204 on the surface 206 facingthe mobile device. Thus, the back of the mobile device may besubstantially suspended from the rest of the back plate 200. Inaddition, this can create a volume 208 between the back of the mobiledevice and the back plate as can be seen in FIG. 9. FIG. 9 is across-sectional view of section A-A (as shown in FIG. 1A).

With reference back to FIGS. 7-8, the surface 206 may also include arecessed portion 210, such that, when a mobile device 20 is adjacent toand engaged with the surface 206, including the raised sides 204, theinterior chamber 208 can be in fluid communication with a bottom side ofthe shell 40. The middle frame 160 may include a corresponding channel170. In such embodiments, this configuration may allow fluidcommunication from the interior chamber 208, to the recessed portion210, to the channel 170, and out of selectively-permeable seal 172 dueto a void 176 located along the perimeter of the gasket 173. This mayalso allow communication between a speaker on the mobile device locatednear the aperture 47 and a microphone on the back of the mobile device.Such communication can allow for noise cancelling features of the mobiledevice to perform without inhibition. It has been found that allowingsome communication within a case between a speaker and microphone usedfor noise cancellation can help ensure that the noise cancellationfeatures of the mobile device function properly.

The location of the interior chamber 208 may be chosen to correspond tofunctional features which may be present on the back surface 24, or onother surfaces of the mobile device 20. The interior chamber 208 may beconfigured to allow such functional features to properly operate.

The surface 206 may be manufactured from materials suitable for creatinga seal such as polymers such as soft plastics and rubbers with a lowshore rating. In some embodiments, silicone rubber may be used.

Back plate 200 may additionally comprise raised protrusions 230extending in a direction perpendicular to the panel 202. These raisedprotrusions may include retention mechanisms 232, such as clips orwings, which are configured to be received within retention receivers168 of the middle frame 160 for attaching the back plate 200 to the baseunit 100.

The inventors here recognize that electronic devices have been or willincreasingly be equipped with biometric sensors that serve as securitymechanisms to verify the identity of the user and facilitate access tothe electronic device. For example, it is contemplated that mobiledevices such as cellular and smart phones, lap tops, and tablets, andthe like, etc. will increasingly employ personal identification andverification biometric sensors as a means to unlock the device to allowthe user to interface with and use the device for one or more of itscapabilities (e.g., send and review email or text message, make orreceive a phone calls, take photos, prepare and edit documents, browseor search the internet, play, use, or download a video, audio, a game oran application, etc.).

Types of biometrics range widely from chemical biometrics (e.g., DNAmatching), to olfactory biometric (e.g., individual's odor), tosignature recognition, to visual biometrics (e.g., ear shape, iris,retina, or face recognition), to finger/fingerprint recognition. Notsurprisingly, the technologies employed to measure these variousbiometrics also range widely. For example, technologies used forfinger/fingerprint recognition alone include the traditional mechanicalmethods (e.g., ink deposition to capture image of the valleys and ridgesof the external surface of a finger), the more conventional opticalmethods (e.g., taking a picture of the finger to directly capture inelectronic form the valleys and ridges of the external surface of afinger), thermal methods (e.g., measuring the heat flux between theridges and sensor surface), ultrasound methods (e.g., using echoreflection of the ultrasonic energy to generate images of the internallayers of skin); and electrical methods (e.g., measuring theconductivity, capacitance, or radiofrequency (RF) field/electrical fieldto generate and capture a digital representation of the internal livelayers of the fingerprint).

In order to facilitate use of such electronic devices, protectiveenclosures or cases, such as described herein, will need to beconfigured and/or constructed in a manner that will allow the user tointerface with the biometric sensor on the device preferably withoutremoval of the protective enclosure or case. More specifically, in thecontext of electrical methods of determining finger/fingerprintrecognition, the user's finger will need to be able to electricallyinterface with the sensor (e.g., to activate and operate the sensor),notwithstanding the protective case or enclosure residing there-between.This is especially significant in the context of protective cases thatfully enclose the electronic device, such as those described herein thathave waterproof capabilities.

Illustrated in FIG. 18 is an embodiment of an electric field fingerprintsensor 303 incorporated into the home button 302 of a mobile device 320,such as the type used in Apple iPhone® and iPad® products. See U.S.Patent Application Publication US 2013/0231046 A1 published Sep. 5,2103, which is hereby incorporated by reference in its entirety. Themobile device depicted in FIG. 18 is basically the same as the mobiledevice 20 previously described, except that the mobile device 320includes a fingerprint sensor 303 that is incorporated into the homebutton. It is contemplated that the home button 302, may be dynamic(e.g., depressible) like conventional iPhone® and iPad® devices or maybe stationary.

Generally the fingerprint sensor 303 includes metallic/conductiveelectrode ring or element 304 that surrounds an array (e.g., one, two,three dimensional array) of electrical sensors 305 that are located ator below the surface 308 of a dielectric (a non-conductive material)layer 307 of the home button 302.

The electrode element 304 may have a circular shape as depicted in FIG.18 or may have an oval, square, rectangular, triangular or othersuitable ring or non-ring shape. The electrode element 304 may be formedas a continuous metallic conductor (e.g., steel) in the shape of acircular ring that forms a perimeter around the home button 302, such asthat depicted herein. However, it should be understood that theelectrode element 304 can be formed of non-continuous segments and maybe configured to surround, fully or partially, the electrical sensors305 contained within the home button 302, which may have the same or adifferent shape from that of electrode element 304.

The electrical sensors 305 may be comprised of an array of capacitiveplates that are coupled to sensor circuitry (not shown) adapted toreceive and processes the sensed signal communicated through the user'sfinger to verify the user's identity. While the sensors 305, includingthe capacitive plates thereof, may be incorporated within the homebutton 302 of the mobile device 320, it is contemplated that theelectrical sensors 305 may be located in other parts of the deviceadjacent to a or removed from the home button 302 and/or outside theelectrode ring element 304, for example in other active or inactiveportions of the touchscreen display/screen of the mobile device 320 orperhaps the sides or the edges (26, 28, 30, and 32) of the device. Inthis regard, it is contemplated that a fingerprint sensor 303 may employmore than one electrode element 304 and more than one group or array ofsensors 305 either in the same region or in one or more regions spacedapart from one another. It is also contemplated that the electrodeelement 304 may have an exterior outer surface 306 that is flat (asdepicted herein), convex, concave or a combination thereof.

The dielectric layer 307 may be formed of any suitable material such asglass, plastic, ceramic, sapphire or sapphire coating etc. that formsthe top outer surface 308 of the home button 302. All or a portion ofthe sensor 305 (e.g., the capacitive plates) may be embedded within thedielectric layer 307 or positioned to the underside of the dielectriclayer 307. While in the illustrated embodiment, the dielectric layer 307is circular and extends to cover only the region of the mobile device320 and in particular the home button 302 within where the sensors 305reside, it should be understood that under some circumstances thedielectric layer 307 may be formed in such a way that it may cover aportion or all of one or more electrode element 304 employed in thefingerprint sensor 303. Thus, in the illustrated embodiment, thedielectric layer 307, forms the top outer surface 308 of the home button302 that is intended to be touched by the user's finger. The top outersurface 308, as illustrated herein, may be slightly concave, oralternatively, the top surface 308 may be flat or slightly convex ortake on other configurations. Thus, while the home button 302illustrated herein may be round or circular in shape, it should beunderstood that it may take other shapes such as and including but notlimited to rectangular, oval, triangular shapes or combinations ofshapes thereof. The top surface 308 of the button 302 may be preferablymade of a dielectric material 307 having a dielectric constant orrelative permittivity ∈_(r) in the range of 2 to 14 (at room temperatureunder 1 kHz) or less. In one embodiment, the top surface 308 of thebutton 302 is made in whole or in part of sapphire or coated with asynthetic sapphire coating that forms the top surface 308.

Generally, in operation, when the user moves a fingertip across theelectrode(s) 304 and capacitive plates in electrical sensors 305, theelectrode element 304 emits electrical energy, such as a signal (forexample within the RF frequency range of 1 to 5 Mhz or other suitablefrequency) into the user's finger and the electrical sensors 305 sense(via the array of capacitive plates) or measure the magnitude of thesignal from the user's finger to capture a digital representation of theuser's fingerprint and verify the users identity. A positiveidentification may allow a user to unlock or access the mobile device320 and do so securely without typing in a password.

The embodiments illustrated in FIGS. 10-14 and the methods of usedescribed herein provide unique solutions that are capable of allowingthe desired operational interaction between the user's finger and thefingerprint sensor 303 on the electronic device through the interposedprotective case. While the embodiments illustrated in FIGS. 10-14 areparticularly configured and adapted for use with a home button 302fingerprint sensor 303 like the one illustrated in FIG. 18, it should beunderstood that scope of the concepts and principles disclosed hereinare equally applicable to other sensor configurations and applicationswithout limitation.

Commonly illustrated in FIGS. 10-14 is a protective case 310 for amobile device 320 with the mobile device 320 contained therein.Generally, other than the interface region overlying the fingerprintsensor, which in the preferred embodiments described herein is comprisedof the fingerprint sensor interface 345 overlying the home button 302and electrode element 304, the protective case 310 employs the sameconstruction as previously described herein with respect to protectivecase 10 illustrated in FIGS. 1-9.

As previously noted, the mobile device 320 may be comprised of a homebutton 302 that includes, or is otherwise surrounded or partiallysurrounded by, one or more electrode elements 304, such as that depictedin the form of a ring in FIG. 18. The electrode element 304 may beinterposed within the front surface 22 of the mobile device 320 and inturn may be surrounded, or partially surrounded, by the adjacent regionsof the front surface 22 including potentially the screen 322 of themobile device 320.

The protective case 310 may be comprised of a light-transmissive panel330 (like the panel 130 described herein in connection with theprotective case 10) for allowing a user to communicate with the touchscreen/display 322 on the mobile device 320. The panel 330 may besurrounded and partially covered by a shell 340 (like the shell 40described herein in connection with the protective case 10). A buttonaperture 126 extends through the front plate 122, like the one describedherein in connection with the protective case 10, and is dimensioned tocorrespond with the dimensions of the home button 302 and thesurrounding electrode element 304. A home button 302 and fingerprintsensor interface 345 resides within the button aperture 126.

In the embodiment illustrated in FIGS. 10-11, the button and fingerprintsensor interface 345 is comprised of a sensor interface conductiveelement 326 residing within the perimeter of the button aperture 126that is configured to be in mating contact with electrode element 304.Accordingly, the top surface 308 of the button is exposed through theaperture of the sensor interface conductive element 326. Thus, in thisembodiment the mobile device 320 would be completely encased except forthe outer surface 308 of the home button 302. A sealing element (notshown) may be interposed between the sensor interface element 326 andthe outer surface 308 of the home button 302, or perhaps embedded intothe sensor interface element 326 at the internal circumference orperimeter, to limit or inhibit ingress of fluid or debris. The sealingelement may be made of a suitable material for creating a seal such aspolymers including soft plastics and rubbers with a low shore rating,such as silicone rubber may be used. The sealing element may also beconfigured to maintain the seal with the outer top surface 308 aroundthe perimeter thereof of the home button 302. In applications where thehome button is dynamic (e.g., depressible) like conventional iPhone andiPad devices the sealing element have sufficient resilience and beconfigured to maintain its seal when the button 302 is depressed. Insuch conventional dynamic/depressible home button design such as thoseemployed by Apple, the depressible home button 302 has limited or nomovement at its outer perimeter. Rather the greatest movement occurs atthe center of the home button 302. Thus, conventional perimeter sealingelements, such as a silicone rubber or the like gaskets that areconforming or pre-conformed to the exterior configuration between theelectrode element 304 and the outer top surface 308 of the home button302 may also be employed in such applications as well. One advantage ofthe embodiment illustrated in FIGS. 10-11 is that it allows for thedynamic functionality of the home button 302. Another advantage of theembodiment illustrated in FIGS. 10-11 is that the electrical sensors 305that contain the arrays of capacitive plates are not obstructed by anintervening element of the protective case 310 and thereby allows directcontact between the finger tissue of the user and outer top surface 308of the home button 302 as intended by the manufacturer of the mobiledevice 320.

FIGS. 12-14 illustrate embodiments of the fingerprint sensor interface345 that in addition to the sensor interface conductive element 326 alsoinclude a protective layer or film element 344 that is dimensioned andconfigured to extend there-between above the electrical sensor 305 thatresides below or within the dielectric layer 307 that forms the topouter surface 308 of the fingerprint sensor 303. The protective element344 can be sealed mechanically, chemically, adhesively or other suitablemeans (e.g., RF welding) or combination of means to the sensor interfaceconductive element 326 and/or the perimeter of the button aperture 126.For example, the protective element 344 may be mechanically press fitwithin a slot residing within the internal perimeter of the sensorinterface conductive element 326 using suitable metallic or polymerpress-fit ring or gasket 346 such as that illustrated in FIGS. 12-13.Alternatively, the protective element 344 may be mechanically supportedby a slot or ledge within the sensor interface conductive element 326the walls of which, as depicted in FIG. 14, may be threaded. A capelement in a form of a ring (not shown) corresponding to the internalshape of the sensor interface conductive element 326 and havingcorresponding threads may be threaded into the sensor interfaceconductive element 326 to mechanically engage the protective element 344to the sensor interface conductive element 326. A gasket or seal (suchas previously described, e.g., made of silicone rubber or other suitableor like material) may be included between the cap element and one orboth sides of the protective element 344 to further enhance theintegrity of the seal between those elements. It should be understoodthat while the embodiment illustrated in FIG. 14 depicts a slot andthread arrangement where the threads are on the top and slot is on thebottom, it should be understood that this arrangement could be reversedsuch that the cap element is threaded into the sensor interfaceconductive element 326 from the opposite side (i.e., the bottom orinside) of that depicted in FIG. 14.

As illustrated in FIGS. 12-14 (which are not to scale), the protectivefilm 344 may be slightly raised above the outer top surface 308 of thehome button 302. However, it should be understood that the distancebetween the outer top surface 308 of the home button and the protectiveelement 344 can be very slight (e.g., less than a 1 mm) or evennon-existent. As illustrated in FIG. 13, the protective element 344should be configured or formed or otherwise constructed to allowsufficient flex to engage the home button 302 and in applications wherethe home button 302 is depressible have sufficient flexibility tooperatively depress the home button 302. In the embodiments illustratedin FIGS. 12 and 14, the protective element 344 is depicted as beinggenerally planar in the unstressed state. However, it should beunderstood that the protective element 344 may be concave or convex or acombination thereof in shape and that such shape may facilitate movementand flexibility of the protective element 344 to allow it to engage withthe underlying sensor 305 and the home button 302. Thus, it iscontemplated that in one aspect the protective element 344 is concave inform and when depressed by the user in operation becomes convex in formto engage the outer top surface 308 of the home button 302.Alternatively, as previously noted the protective element 344 may beformed to correspond with the underlying shape of the fingerprint sensor303 and/or home button 302.

One advantage of the embodiments illustrated in FIGS. 12-14 is that whenthe mobile device 320 is enclosed within the case 310, there is noportion of the mobile device 320 that is unprotected or exposed not eventhe top outer surface 308 of the sensor 303. In addition, the protectivefilm element may provide yet a further obstacle or barrier to passage ofliquids such as water into the electronic circuitry of the mobile device320. It should be understood that the use of the protective film element344 may be employed with or without the sealing element configured tomaintain the seal with the outer top surface 308 around the perimeterthereof of the home button 302 described above in connection with theembodiment depicted in FIGS. 10-11.

The protective element 344 may be manufactured from any suitabledielectric or polymer material. For example, it is contemplated that theprotective film 344 may be made of a transparent or a non-transparent,elastic, polyester film, polyethylene, or biaxially-orientedpolyethylene terephthalate (boPET). In one embodiment, the protectivefilm 344 may be extruded PET such as that sold under the Mylar® tradename by of DuPont™. For example, it is contemplated, the protectivefilm, such as that formed of PET (e.g., Mylar) or other polymer ordielectric material may be 0.1 to 1 mm in thickness; between 0.03 to 0.5mm in thickness; between 0.01 to 0.1 mm in thickness; and perhaps morepreferably between 0.03 to 0.075 mm in thickness and perhaps even morepreferably between 0.036 to 0.05 mm and perhaps even more preferably at0.05 mm+/−0.01 mm. It is contemplated that the protective film layer maybe 0.01 mm in thickness or less.

While a flexible film protective element 344 is described herein, itshould be understood that the protective element 344 may be formed ofone more components with a flexible region and a less flexible or morerigid region. The flexible region may be formed at the perimeter of theelement and interface with or be in proximity to the sensor interfaceconductive element 326 as described above and the more rigid region maybe more centrally located within the boundaries of the protectiveelement 344. Alternatively, the more rigid region may be formed at theperimeter of the element and interface with or be in proximity to thesensor interface conductive element 326 as described above and the moreflexible region of the protective element 344 may be more centrallylocated within the boundaries of the protective element 344. The morerigid portion of the protective element 344 may be achieved byemployment of different materials (e.g., glass, sapphire, ceramic, rigidplastic or other suitable dielectric material) relative to the moreflexible regions or may be achieved by varying (e.g., increasing) therelative thickness of the protective element 344 so that perimeterregions of the protective element 344 may be thinner or thicker than theinternal regions of the protective element 344.

The sensor interface conductive element 326, which is commonly disclosedin the embodiments depicted in FIGS. 10-14, is generally in a form of aring that includes an upper portion 332 that is intended and configuredto interface or come into contact with the user's finger and a lowerportion 328 that is intended and configured to interface with exposedregions of the electrode element 304 of the fingerprint sensor 303. Thelower portion 328 includes a bottom surface 334 that is dimensioned andshaped to correspond with and mate to the external configuration of thetop outer surface 306 of the electrode element 304 of the fingerprintsensor 303. In the embodiment illustrated in FIGS. 10-11, the respectivemating surfaces for bottom surface 334 of the sensor interfaceconductive element 326 and the top outer surface 306 of the electrodeelement 304 of the fingerprint sensor 303 are generally in a form of aflat planar ring. In this embodiment, the lower portion 328 of thesensor interface conductive element 326 has a generally rectangularcross-section. In contrast, in the embodiment illustrated in FIGS.12-14, the respective mating surfaces for bottom surface 334 of thesensor interface conductive element 326 and the top outer surface 306 ofthe electrode element 304 of the fingerprint sensor 303, while also inthe form of a ring, are not flat. Rather, in this embodiment, the lowerportion 328 of the sensor interface conductive element 326 has agenerally trapezoidal cross-section. Accordingly, the bottom portion328, defined by the bottom surface 334, may have various cross-sectionalshapes comprising of a lower portion 328 having a rectangular crosssection with a bottom base 334, and an upper portion 332 having atrapezoid-like cross section with a sliding lateral side 336 and a topbase 338. In other embodiments, other cross-sectional shapes can be usedfor the button aperture 326.

The mating interface between the top surface 306 and bottom surface 334should provide sufficient contact to facilitate communication of theelectrical energy emitted by the electrode element 304 to the user'sfinger via the sensor interface conductive element 326 when the sensoris active or in use. It is also contemplated that the electrode element304 may serve the dual purpose of also detecting the presence of the auser's finger to activate the sensor and hence the mating interfacebetween the top surface 306 and bottom surface 334 should preferablyprovide sufficient contact to facilitate communication of the electricalenergy emitted by the electrode 304 to the user's finger via the sensorinterface conductive element 326 to activate the sensor by sensing thepresence of the user's finger atop the upper portion 332 of the sensorinterface conductive element 326 to activate the sensor 303. Thetrapezoidal cross-sectional shape may be advantages in maintainingsufficient conductive contact between the top surface 306 and the bottomsurface 334 by providing a spaced relationship between its bottomsurface 334 and the surface regions of the mobile device 320 adjacent tothe outer perimeter of the electrode element 304 (such as the screen322, of the mobile device).

The mating surfaces 334 and 306 of the interface conductive element 326and the electrode element 304 respectively may be something other thanflat and circular. For example, exposed surface 306 of the electrodeelement 304 may be convex or beveled (inwardly or outwardly relative tothe perimeter) and may have any ring shape (e.g., oval, square,rectangular, triangular, circular, combination thereof). The ring may becomprised of an electrode element 304 that is formed of continuousmetallic element or discontinuous metallic elements spaced apart fromanother to define a ring. The corresponding mating region of the bottomsurface 334 of the sensor interface conductive element 326 would in apreferred implementation have a shape that corresponds to the ring shapeof the electrode element 304 and a surface that mirrors that of the topouter surface 306 of the electrode element 304 so that when in operationthe two surface 306 and 334 are mated with sufficient contact and/orproximity to facilitate communication of the electrical energy emittedby the electrode element 304 to the user's finger via the conductiveelement 326 of the sensor interface to activate and/or use the sensor305.

It should be understood that FIGS. 10-14 are for illustrative purposesonly and are not to scale. Dimensionally, the height (dimension from thebottom surface 334 to the top surface 338) of the sensor interfaceconductive element 326, may in a preferred embodiment be 2-3 mm+/−1 or 2mm or even less. As previously described, the sensor interfaceconductive element 326 is formed of a conductive material that caneffectively communicate electrical signals from the ring electrodeelement 304 to the user's finger to activate and use the fingertipsensor 305. It is contemplated that any metallic conductive material maybe employed, including stainless steel. In a preferred embodiment thesensor interface conductive element 326 is formed of the same conductivematerial as that which forms the electrode element 304 of the mobiledevice 320, which the sensor interface conductive element 326 isconfigured to interface with. In another preferred embodiment, thesensor interface conductive element 326 is formed of conductive materialthat has the same, less, or greater electrical resistivity than thematerial that forms the electrode element 304 of the mobile device 320,which the sensor interface conductive element 326 is configured tointerface with.

The button aperture in the shell 40 that receives the sensor interfaceconductive element 326 can be formed as part of the case 310 via insertmolding, or any other mechanism known in the art. For example, material,such as plastic, for the shell 340 of the case 310 can be injected intoa mold that contains the pre-placed button aperture and sensorconductive element 326 to form a single molded piece with a surrounding,or partially surrounding, shell 340.

In operation, electrical signals, for example, RF signals emitted fromthe electrode element 304 are communicated via the sensor interfaceconductive element 326 to the user's overlying finger (e.g. into theliving layer of the skin of the finger). A resulting RF field isdetected by the electrical sensors 305 including the capacitive platesof the fingerprint sensor 303 either directly through the top surface308 of the dielectric layer 307 of the sensor 305 or via the interveningdielectric protective element 344. Upon detection, the sensor determinesvia its sensing circuitry whether the finger detected RF field matchesan authorized fingerprint set within the fingerprint sensor 305.

It is further contemplated that in operation, the user may first swipeor place a finger over the fingerprint sensor interface 345 of theprotective case 310 to activate or unlock the enclosed or protectedelectronic device as previously described. In some circumstances, it maybe preferable that the user set (or condition) the sensor 303 with theprotective case on the device, and then going forward swipe or place thefinger over the fingerprint sensor interface 345 of the protective case310 to activate or unlock the enclosed or protected electronic device320. By setting the sensor with the protective case 310 in place, thesensor 303 will be conditioned to sense the user's finger with theprotective case 310 in place and in particular through the fingerprintsensor interface 345, which may make the sensor 303 more reliable undersuch actual use conditions going forward. Thus, it is contemplated thatin operation the user first encase or enclose the electronic device 320within the protective case 310 so that the fingerprint sensor interface345 of the protective case 310 overlies the finger print sensor 303 ofthe electronic device 320 in the intended or configured operationalmanner or placement. Then, the user sets or initializes the fingerprintsensor 303 with the protective case 310 on the electronic device 320 byplacing a finger on top of the fingerprint sensor interface 345 toactivate and set/initialize the fingerprint sensor 303 to recognize theuser's finger. In this way, the fingerprint sensor 303 is conditioned torecognize the user's finger as sensed through the fingerprint sensorinterface 345 of the protective case 310 that overlies and interfaceswith the fingerprint sensor 303 as described. Once the fingerprintsensor 303 is set, the user then swipes or places the finger over thefingerprint sensor interface 345 of the protective case 310 to activateor unlock the enclosed or protected electronic device 320.

In situations where the device fingerprint sensor 303 is capable ofrecognizing multiple fingerprint images as valid images, it iscontemplated that the user may condition the fingerprint sensor 305 onthe device 320 under a first condition without the protective case 310and under a second condition with the protective case 310 enclosing thedevice as previously described above. It is also contemplated that theuser may use the same finger or one or more different fingers whensetting the fingerprint sensor 305 under those various conditions toallow for reliable verification of the user's finger by the mobiledevice 320 when the device 320 is enclosed and protected in the case 310as well as when it is removed or is used outside the case.

In some devices, one or more proximity sensors 402, 404 can be locatednear the microphone aperture 121, the speaker aperture 124, the cameraaperture 125, or other places on the device and serve to detect when thedevice is in close proximity to an external objects (e.g., a user'spocket or face, etc.) so that the device can automatically turn off thescreen or other features to facilitate, among things, powerconservation. The inventors here have recognized, as illustrated in FIG.15, that when the mobile device 320 is housed within the protective casesuch as previously described (e.g., 10 and/or 310 above), a space 410can develop between the internal surface of the protective case (e.g.,the panel 330) and the screen surface 322 of the mobile device 320 on ornear the overlying regions of the device that house the proximitysensors 402, 404. As a result, the proximity sensors 402, 404 may inoperation detect light reflections 412 r, 414 r generated from eachother, or perhaps from themselves that are reflected back as a result ofthe protective case rather than an external object thereto as intended.This, situation may also occur even when there is no space 410 as aresult of the placement of a discontinuous component above the proximitysensor. In all such situations, a false or undesired trigger of theproximity sensors may occur, which in turn results in an unintendeddisabling of the touch screen interface of the mobile device 320. Forusers of protective cases this can be a frustrating experience.

FIG. 16 shows a sectional view illustrating the proximity sensors 402,404 of the mobile device 320 with the protective case 310 having aprivacy layer 430 for correcting the problem of reflection from thescreen 330. In the present embodiment, a privacy layer 430 is placedbetween the screen 330 of the case 310 and the screen surface 322 of themobile device 320. The privacy layer 430 is coated, layered glued orotherwise positioned underneath the region of the panel 330 of the case310 configured to overlie the proximity sensors 402, 404.

The privacy layer 430 may be comprised of a polarizer element whichallows the passing of light in a certain specified direction ororientation (e.g., perpendicular to the panel 330) and blocks or absorbslight that impinges on it from other directions. Thus, as illustrated inFIG. 16, light 412, 414 that is radiating in a direction other than thepass through direction will neither pass or be reflected back to one ofthe sensors. Yet light waves 422 r, 424 r, which are reflected back byobjects external to the device, will come back to the proximity sensors402, 404 to allow for the intended operation of those sensors.

FIG. 17 illustrates another embodiment that is capable of limitingundesired proximity sensor triggers. Specifically, FIG. 17 shows asectional view illustrating the proximity sensors 402, 404 of the mobiledevice 320 with the protective case 310 and panel 330 wherein anon-passing area 434 (e.g., a light absorbing region) is positioned onthe panel 330 in a region residing between the two proximity sensors toprovide an isolation boarder or ring around or between the proximitysensors to isolate them from one another. The non-passing or lightabsorbing area 434 can be formed by coating, layering or gluing on theunderside of the transmissive panel 330 a light-absorbing material 434,such as a dark ink or black body and/or including polarizing elements.Light 412, 414 radiating into the light-absorbing material 434 will becompletely or significantly absorbed to limit or preclude beingreflected back to the proximity sensor and thereby avoid undesiredtriggering of the proximity sensor. Yet light beams 422 r, 424 r, whichare reflected back by objects external to the device, are still capableof returning back to the proximity sensors 402, 404 to trigger thesensor under the desired circumstances.

FIGS. 19-27 illustrate various aspects of additional implementations ofa protective case 310 a, which other than described in relevant partherein, are generally the same as the protective cases previouslydescribed.

Specifically, FIG. 19 is a top view of a protective case 310 a thatincludes the shell 340 a (which includes e.g., the base unit 100, backplate 200, and cap assemblies and subcomponents as previouslydescribed), and also includes another exemplary implementation of afingerprint sensor user interface 345 a. The user interface 345 a inthis implementation is also comprised of a conductive element that isconfigured to functionally interface with the electrode element 304 of afingerprint sensor 303, such as that depicted in FIG. 18. However, theconductive element 326 a in this implementation is in the form of ametallic or conductive ink that is bonded or otherwise printed, adhered,or layered on opposing sides of a substrate or protective film element344 a in a location that is configured to at least in part overly thefingerprint sensor 303 of the mobile device 320 that the case 310 a isconfigured to receive.

FIG. 20 is a more detailed top view of the lower region of theprotective case 310 a containing the fingerprint sensor user interface345 a illustrated in FIG. 19. The shaded region is the conductiveelement of the fingerprint sensor user interface that resides below thelight-transmissive panel 330 a overlying the cell phone screen andextends across the home button aperture contained therein.

As illustrated in shadow in FIGS. 19-20, in order to visually concealportions of the construction, portions of the internal surface of thelight-transmissive panel 330 a may be silkscreened with black or othersuitably colored ink. In the embodiment illustrated in FIGS. 19 and 20,the shadow line 331 around the perimeter of the light-transmissive panel330 a defines the region on the panel (outside the shadow line) where ina preferred implementation the underside of the panel 330 a issilkscreened with an ink (e.g., black or other colored ink) thatconceals or renders the perimeter region of the panel 330 a opaque orless than fully transparent as compared to the more internal regions ofthe panel 330 a, which would be transparent to allow for fullunobstructed view of the underlying mobile device screen.

FIG. 21 is an exploded perspective view of the lower region of the frontframe 122 a of the base unit 100 of the protective case 310 aillustrated in FIGS. 19-20. In order to provide a better illustration ofthe lay-up of the fingerprint sensor user interface 345 a and thesurrounding components, the middle frame 160 of the base unit 100 is notillustrated.

As illustrated in FIG. 21, the front frame 122 a includes a rigid shell340 a frame that defines a screen aperture 127 a, such as previouslydescribed in connection with FIGS. 1-10 above. A light-transmissivepanel 330 a (e.g., tempered or laminated glass) is mounted at itsperimeter regions to the inside wall or surface of the rigid shell 340 aframe using an adhesive layer 138 a that conforms in shape with themounting surface on the shell 340 a as previously described. The regionof the shell 340 a configured to be adjacent to the home button ismodified from the prior embodiments in that rather than entirelysurrounding the home button, as illustrated in FIGS. 1A, 2A, and 10-14,it is configured to surround the home button region only along the lowerbottom perimeter region.

The light-transmissive panel includes a home button aperture 134 a. Inthe implementation illustrated, the home button aperture 134 a includesa beveled edge 135 and is dimensioned (e.g., D1) to encompass andcorrespond in dimension with the underlying fingerprint sensor (e.g., D1illustrated in FIG. 18) for which the case is designed for. The bevelededge facilitates greater access by the user finger. It is contemplated,however, that the dimensions of the home button aperture 134 a may belarger or smaller than the dimensions of the fingerprint sensor 303. Forexample, it is contemplated that the dimensions of the home buttonaperture 134 a may be smaller so that a portion (or all) of theelectrode element is not contained within the aperture 134 a but fallsoutside the aperture 134 a. For example, the aperture 134 a may have adiameter (D1 in FIG. 21) that is between the outer and inner diameter ofthe electrode element 304 depicted in FIG. 18 so that when the mobiledevice 320 depicted in FIG. 18 is positioned within the case the innerradial portion of the electrode element 304 is located below and withinthe perimeter of the aperture 134 a and an outer radial portion of theelectrode element 304 is located outside of the perimeter of theaperture 134 a under the glass panel 330 a. By way of another example,the aperture 134 a may have a diameter (D1 in FIG. 21) that is smallerthan the inner diameter of the electrode element 304 depicted in FIG. 18so that when the mobile device 320 depicted in FIG. 18 is positionedwithin the case the entire electrode element 304 is located outside ofthe perimeter of the aperture 134 a under the glass panel 330 a.Alternatively, it is contemplated that the aperture 134 a may have adiameter (D1 in FIG. 21) that is greater than the outer diameter of theelectrode element 304 depicted in FIG. 18 so that when the mobile device320 depicted in FIG. 18 is positioned within the case the entireelectrode element 304 is located within the perimeter of the aperture134 a. In a preferred implementation, it is contemplated that thediameter of the aperture 134 a be 1 to 3 millimeters greater than thediameter or outer dimensions of the underlying fingerprint sensor 303.

Further illustrated in FIG. 21 is another implementation of thefingerprint sensor interface 345 a that includes a protective filmelement 344 a and conductive element 326 a that can be in the form ofone or more conductive ink layers 326 a 1 and 326 a 2 bonded orotherwise applied or adhered onto a substrate element 344 a. Thefingerprint sensor interface 345 a can be laminated to the glass panel330 a with an adhesive layer 138 b like the adhesive 138 previouslydescribed. In order to facilitate direct contact between the substrateelement 344 a and fingerprint sensor, the adhesive layer 138 b mayinclude an aperture 139 that is dimensioned to correspond with theaperture 134 a in the glass panel 330 a. The dimension of the aperture139 may be greater than the dimension of aperture 134 a so that thefingerprint sensor interface 345 a is not bonded or otherwise attachedall the way to the perimeter edge region of the home button aperture 134a of the glass panel 330 a. In order to further improve the waterresistance of the protective case, the adhesive 138 a (as is the casefor all the adhesives referenced herein) may be waterproof or waterresistant. An additional laminate layer 350 a may be applied over thefingerprint user interface 345 a after the interface 345 a is attachedto the panel 330 a via the adhesive 138 b. The laminate layer 350 a maybe an optically clear film with an adhesive on the inner side thatallows it be glued or bonded over the fingerprint sensor user interface345 a. In the embodiment illustrated in FIG. 21 the laminate layer 350 aextends and is bonded over the full, or substantially the full, lengthand width of the inner surface or inner side of the glass panel 330 a ontop of the fingerprint sensory user interface 345 a. As illustrated inFIG. 21, the laminate layer 350 a includes an aperture 351 that isconfigured to facilitate direct contact and interaction between thesubstrate element 344 a and the underlying fingerprint sensor 303.

FIG. 22 is an exploded perspective view of an exemplary lay-up of theconductive and substrate elements 326 a 1, 326 a 2 and 344 a,respectively, of the fingerprint sensor user interface 345 a of theprotective case 310 a that is illustrated in FIGS. 19-21. The lay-up iscomprised of a substrate or protective element 344 a that that islayered with conductive ink 326 a 1 and 326 a 2 on opposing sides. Theopposing conductive ink layers 326 a 1 and 326 a 2, although separatedby the substrate sheet 344 a, are as explained in more detail belowlayered onto the substrate sheet in such a manner so as to allow for atleast some physical and/or electrical contact with each other. Eachconductive ink layer 326 a 1 and 326 a 2 includes a primary region(e.g., within the ring region) that is configured to reside above theelectrode element 304 of a fingerprint sensor 303 and one or moresecondary regions in the form of projections that extend radiallyoutward from the primary region. The fingerprint sensor user interface345 a may also be sandwiched within opposing layers of a protectivecoating 347 a and 347 b. The protective coating may also be formed ofconductive ink or material.

In construction, the substrate material perhaps provided in a roll, iscut into appropriate sheets and cleaned with appropriate cleaningsolution and/or cleaning cloth. As was the case with the protective film344, the substrate 344 a may be made of a transparent or anon-transparent, elastic, polyester film, biaxially-orientedpolyethylene terephthalate (boPET), polyethylene terephthalate (PET),polyethylene terephthalate polyester (PETP), or any another suitablematerial. For example, it may be extruded PET such as that sold underthe Mylar® trade name by of DuPont™ or other polymer or dielectricmaterial. The substrate should be durable enough to withstanding thewear that is accompanied with repeated use and also preferablywaterproof or water resistant. It is contemplated that the substrate 344a material may have a thickness of between 0.01 mm to over a 1 mm;between 0.03 to 0.5 mm; between 0.01 to 0.1 mm; perhaps more preferablybetween 0.03 to 0.075 mm; perhaps even more preferably between 0.036 to0.05 mm; and perhaps even more preferably at 0.05 mm+/−0.01 mm. It iscontemplated that the substrate or protective film 344 a may be aslittle as 0.01 mm or less and formed of polymer material. The thicknessof the substrate depends on the conductive coating used, its durabilityonce incorporated in the case, and its ability to be sufficiently RFtransparent to allow the RF emitted from the electrode element 304 to bereceived by the electrical sensors 305 of the fingerprint sensor 303. Itshould also be understood that the substrate 344 a (at least the portionresiding over the electrical sensors 305) like the protective film 344is preferably a dielectric material. It should be understood that while,the embodiments of the fingerprint sensor user interface depictedherein, are shown with an conductive element, it is contemplated thatthe user interface may not require a conductive element but may becomprised of a very thin RF transparent film. However, such a thin filmmay suffer from unsuitable durability or deform with time and use.

Once the substrate is prepared, the conductive ink layer 326 a 1 isapplied in any suitable manner, for example by silkscreen, onto thesubstrate. The conductive ink layer 326 a is allowed to dry under roomtemperature and pressure conditions and/or is dried using appropriateair and/or heat mechanisms. In a preferred embodiment, the conductiveink is silver based conductive material. However, any suitableconductive material (copper, gold, steel, carbon, etc.) may be used. Theconductive ink material may have an electrical conductivity that is theless, the same, or greater than the electrical conductivity of theelectrode element 304 of the fingerprint sensor. It may be preferable,however, to employ a conductive ink material that has at least the sameor greater electrical conductivity than that of the electrode element304.

Once the first conductive ink layer 326 a 1 is applied to one side ofthe substrate 344 a and dried, punch through holes 352 are formedthrough the conductive ink layer 326 a 1 and underlying substrate 344 a.The punch through holes 352 are formed on the right, left side, or bothsides of the primary region of the conductive ink layer 326 a 1 throughthe projections that form the secondary regions of the conductive inklayer. The purpose of the punch through holes 352 is to facilitateelectrical communication (e.g., physical contact) between the opposingconductive ink layers 326 a 1 and 326 a 2. In construction, the punchingaction folds the conductive ink layer 326 a 1 slightly into the opposingside of the substrate element 344 a, such that when the secondconductive ink layer 326 a 2 is applied it would flow into the punchthrough holes 352, or the perimeter regions thereof, so as to touch thesides of the first conductive print layer 326 a 1.

Once the punch through holes 352 are formed, the unprinted opposing sideof the substrate is cleaned, as previously described, and the conductiveink layer 326 a 2 is applied (e.g., via silkscreen or other suitableprocess or method) to the opposing side of the substrate element 344 aand dried. After drying, the first side may be cleaned again and anothercoating of conductive ink 326 a 1 may be applied to the first side ofthe substrate to ensure electrical communication and physical contactbetween opposing sides of the conductive ink layers 326 a 1 and 326 a 2.This process can be repeated as necessary. Once the conductive inkcoatings 326 a 1 and 326 a 2 are applied and dried, the fingerprintsensor user interface pre-form can be cleaned again and protectivecoatings 347 a and 347 b can be applied over the previously laidconductive ink coatings, a layer on each side at a time and then cured,such as with ultraviolet light. The protective coatings 347 a and 347 bmay be an ultraviolet curable ink and may be comprised of eitherconductive and/or non-conductive material. The protective coatings maybe transparent, semi-transparent, or opaque and may be include coloringsuch as black, white, red, blue, green, yellow, orange, pink, etc. thatis selected to correspond, match or compliment the externally visiblecoloring scheme of the protective case 310 a. It is contemplated thatthe coatings 347 a and 347 b be comprised of a material and be of athickness as to not interfere with the electrical communication betweenthe electrode element 304, the conductive element 326 a and the user'sfinger.

Once the protective coatings 347 a and 347 b are applied and cured,another set of punch holes 353 are, in an exemplary construction, formedthrough the entire pre-form of the fingerprint sensor user interface 345a. The purpose of the second set of punch holes, is to position thepre-form into a mold that forms the pre-form into a three dimensionalconfiguration (e.g., via heat formed process) that corresponds, in partor in whole, to the external surfaces of the fingerprint sensor 303including the outer surface overlying the electrical sensors 305 and/orthe outer surface of the electrode element 304. Once formed the pre-formof the fingerprint sensor user interface can be die-cut to the desiredshape or otherwise finished as needed prior to incorporation into theprotective case 310 a.

The position and size of the punch through holes 352 and 353 can beoptimized so that they are spaced far enough away from the home buttonaperture 134 a in the glass panel 330 a to ensure that there issufficient surface area on the glass panel 330 a for the waterproofadhesive 138 b to fully surround the punch holes 352 and 353 to sealthem from the aperture 134 a in the glass panel 330. A strong andwaterproof bond can thus be established. While it is contemplated thatthe light-transmissive panel 330 a be constructed of glass, it should beunderstood that as previously noted, the light-transmissive panel 330 amay be comprised of any rigid or flexible material that has sufficienttransparency for the user to view the mobile device screen.

FIG. 26 is flow chart reciting selective steps 1010, 1020, 1030, 1040,and 1050 for a process 1000 for making a protective case for a biometricsecured mobile device that includes a biometric sensor user interfacesuch as those described herein. FIG. 26 is basically a summary of theconstruction of the fingerprint sensor user interface constructionpreviously detailed above.

FIGS. 23A-B and 24A-B are some alternative pattern variations for theconductive ink layers 326 a 1 and 326 a 2. Specifically, FIG. 23A is anillustration of an alternative conductive ink configuration for thefingerprint sensor user interface illustrated in FIGS. 19-22, whereinthe conductive ink element 326 a includes a primary region that isconfigured to reside above the electrode element 304 of a fingerprintsensor 303 and multiple secondary regions in the form of projectionsthat extend on the left and right side of the primary region radiallyoutward therefrom. As in the case of the fingerprint sensor userinterface depicted in FIG. 22, the opposing conductive ink layers are inphysical and/or electrical contact with each other and are positioned onopposing sides of a substrate sheet. FIG. 23B is an exploded view thesubstrate 344 a and the opposing layers of the conductive ink 326 a 1and 326 a 2 of the alternative conductive ink configuration illustratedin FIG. 23A.

FIG. 24A is an illustration of another alternative conductive inkconfiguration for the fingerprint sensor user interface illustrated inFIGS. 19-22, wherein the conductive ink element 326 a includes a primaryregion that is configured to reside above the electrode element 304 of afingerprint sensor 303 and a secondary region in the form of singleprojections that extends downward and radially outward from the primaryregion. As in the case of the fingerprint sensor user interface depictedin FIG. 22, the opposing conductive ink layers are in physical and/orelectrical contact with each other and are positioned on either side ofa substrate sheet. In this implementation, however, physical andelectrical contact between the opposing layers of conductive ink 326 a 1and 326 a 2 is achieved, not by means of the punch through holes 352 aspreviously described, but rather by contact of the conductive ink layersat the edge region of the substrate. Because there are no punch throughholes to mediate the electrical communication between the layers, thisimplementation may be capable of adding structural integrity to theconstruction. It may also limit the region of the panel 330 a that wouldneed to be concealed from view by a silkscreening an opaque ink and thuspotentially provide more flexibility in design. FIG. 24B is an explodedview of the substrate 344 a and the opposing layers of the conductiveink element 326 a 1 and 326 a 2 of the alternative conductive inkconfiguration illustrated in FIG. 24A.

FIG. 25 is a partial exploded view of a modified embodiment of theprotective case 310 a illustrated in FIGS. 19-24, wherein the conductiveelement is comprised of a first component 326 a that is printed orotherwise, applied, inked or layered on opposing sides of a substrateelement such as that depicted in FIGS. 19-24 and a second electricallyconductive component 326 generally similar to the conductive elementdepicted in FIGS. 10-14, which is positioned to overly and beproximately located to, or in physical contact and/or electricalcommunication with the upper surface of the first component of theconductive element.

FIG. 27 is a partially exploded perspective view of the top region ofthe front frame 122 a of the protective case 310 a illustrated in FIG.19 providing a more detailed view of a polarizing element 430 aconfigured to reside within the case 310 a above the proximity sensors402 and 403 illustrated in FIG. 16 of the mobile device for which thecase is configured to receive. More specifically, the polarizing element430 a is contained within a compartment that is defined by an enlargedspeaker aperture 132 a contained within the light-transmissive panel 330a and separated from the mobile device by a laminate panel 350 a thatoverlies the light-transmissive panel and extends over the regions ofthe speaker aperture 132 a wherein the proximity sensor 430 isconfigured to reside adjacent thereto or below.

Although this invention has been disclosed in the context of certainpreferred embodiments and examples, it will be understood by thoseskilled in the art that the present invention extends beyond thespecifically disclosed embodiments to other alternative embodimentsand/or uses of the invention and obvious modifications and equivalentsthereof. In addition, while a number of variations of the invention havebeen shown and described in detail, other modifications, which arewithin the scope of this invention, will be readily apparent to those ofskill in the art based upon this disclosure. It is also contemplatedthat various combinations or sub-combinations of the specific featuresand aspects of the embodiments may be made and still fall within thescope of the invention. Accordingly, it should be understood thatvarious features and aspects of the disclosed embodiments can becombined with or substituted for one another in order to form varyingmodes of the disclosed invention. Thus, it is intended that the scope ofthe present invention herein disclosed should not be limited by theparticular disclosed embodiments described above, but should bedetermined only by a fair reading of the claims that follow.

Similarly, this method of disclosure, is not to be interpreted asreflecting an intention that any claim require more features than areexpressly recited in that claim. Rather, as the following claimsreflect, inventive aspects lie in a combination of fewer than allfeatures of any single foregoing disclosed embodiment. Thus, the claimsfollowing the Detailed Description are hereby expressly incorporatedinto this Detailed Description, with each claim standing on its own as aseparate embodiment.

1. A removable protective case for a mobile device having a biometricsensor comprising an electrode element for emitting electric energy anda sensing element residing below a dielectric region for detectingemitted electric energy passing through a user's finger, the protectivecase comprising a user interface that includes a conductive elementattached to a light-transmissive panel and configured to correspond inshape and be in proximate electrical contact with the electrode elementof the fingerprint sensor to facilitate communication of the electricenergy emitted by the electrode element to a user's finger overlyingsaid conductive element.
 2. The protective case of claim 1, wherein theconductive element is stainless steel and in the shape of a circularring.
 3. The protective case of claim 1, wherein the conductive elementis constructed and configured to communicate electric energy having aradio frequency when the conductive element is in proximate contact withthe electrode element of the sensor.
 4. The protective case of claim 1,wherein the user interface of the protective case further includes adielectric element that is configured over the dielectric region of thesensor.
 5. The protective case of claim 4, wherein the dielectricelement is configured to be depressible.
 6. The protective case of claim1, wherein the conductive element is sealed to the perimeter of thedielectric region of the sensor.
 7. The protective case of claim 1,wherein the conductive element is comprised of a hardened layer ofconductive ink.
 8. The protective case of claim 1, wherein theconductive element is comprised of two hardened layers conductive inkthat are spaced apart and in electrical contact with one another in atleast one discrete region.
 9. The protective case of claim 1, whereinthe conductive element is comprised of one or more layers of conductiveink and wherein said conductive ink is hardened upon opposing sides of asubstrate element.
 10. The protective case of claim 9, wherein thesubstrate element is comprised of a polymer sheet less than 0.1millimeters in thickness.
 11. The protective case of claim 9, whereinthe substrate element is comprised of a dielectric material having adielectric constant of less than
 14. 12. The protective case of claim 9,wherein the substrate element is configured to extend over thedielectric region of the sensor.
 13. The protective case of claim 8,wherein the conductive ink layers are separated by a substrate elementthat includes through holes configured to facilitate electrical contactbetween the conductive ink layers.
 14. The protective case of claim 1,wherein the light-transmissive panel is comprised of glass.
 15. Theprotective case of claim 1, wherein the light-transmissive panel iscomprised of a flexible polymer.
 16. The protective case of claim 5,wherein the dielectric element is attached to a flexiblelight-transmissive panel that is more rigid than the dielectric element.17. The protective case of claim 1, wherein the user interface isthree-dimensionally configured to correspond in shape with at least someregion of the biometric sensor of the mobile device that it isconfigured to receive.
 18. The protective case of claim 1, wherein theuser interface is at least partially interposed within an aperture ofthe light-transmissive panel.
 19. The protective case of claim 18,wherein the aperture of the light-transmissive panel is configured to bedimensionally larger than the underlying electrode element of thebiometric sensor for which the protective case is configured to receiveand protect.
 20. The protective case of claim 1, further comprising alight-transmissive laminate that is laminated to the inner facingsurface of the light-transmissive panel and surrounds the userinterface.
 21. The protective case of claim 9, wherein thelight-transmissive panel is configured to substantially cover at leastone proximity sensor of the mobile device, and wherein a polarizingelement positioned on the light-transmissive panel is configured toreside above the at least one proximity sensor of the mobile device forwhich the protective case is configured to enclose.